Download Dunkirk Q95M-200 Troubleshooting guide

95M-200
Gas-Fired Direct Vent
Modulating Hot Water Boiler
Control Manual And
Troubleshooting Guide
P/N 240006104, Rev. C [04/09]
WARNING
!
Revise boiler control parameters only if you fully understand the
purpose and result of the changes. Tampering without understanding the control settings in this manual will void the warranty and can result in unreliable operation, with possible severe
personal injury, death, or substantial property damage.
WARNING
!
This document must only be used by a qualified heating installer
or service technician. Read all instructions, including the Installation Manual (P/N# 240006103), the Parameter Guide (P/N#
240006105), the User’s Information Manual (P/N# 240006106),
and this Control Manual and Operating Instructions before
attempting to program the control, and be sure to perform all
steps in the order specified. Failure to comply could result in
severe personal injury, death, or substantial property damage.
NOTICE
IMPORTANT: Installation must comply with local requirements
and with the National Fuel Gas Code, ANSI Z223.1 for U.S.
installations or CSA B149.1 or B149.2 for Canadian installations.
NOTICE
DO NOT DESTROY THESE INSTRUCTIONS!!
Please read carefully and keep in a safe place for future reference.
H
2
95-200M GAS FIRED DIRECT VENT MODULATING HOT WATER BOILER
Control manual and operating instructions
Printed in USA • Made In USA
Table of Contents
I - Safety Symbols and Warnings............................................................................................................................3
II - Operating Information.......................................................................................................................................4
III - Modulating Control Features...........................................................................................................................6
IV - Boiler Startup.....................................................................................................................................................6
V - Checkout Procedures and Adjustments...........................................................................................................9
VI - Detailed Sequence of Operation................................................................................................................... 12
VII- Service Hints................................................................................................................................................... 13
VIII - Troubleshooting........................................................................................................................................... 14
IX - User Interface Quick Reference..................................................................................................................... 21
X- Installation And Checkout Certificate............................................................................................................. 26
NOTICE
Keep this manual near boiler and retain for future reference.
I - Safety Symbols and Warnings
The following defined symbols are used throughout this manual to notify the reader of potential hazards of varying risk levels.
IMPORTANT: Read the following instructions completely before installing!!
DANGER
!
Indicates an imminently hazardous situation which, if not
avoided, WILL result in death, serious injury or substantial
property damage.
WARNING
!
Indicates an imminently hazardous situation which, if not
avoided, may result in death, serious injury or substantial property damage.
CAUTION
!
Indicates an imminently hazardous situation which, if not
avoided, may result in injury or property damage.
NOTICE
Indicates information which should be followed to ensure proper
installation and operation.
3
II - Operating Information
unless the application is specially engineered for other temperature. DHW heating default setting is 180°F.
This boiler is controlled by a microprocessor electronic control that
senses outlet water temperature, return water temperature, and outdoor temperature (when a factory supplied, field installed outdoor
sensor is installed). This information (plus input from external limit
and operating controls) is used to regulate boiler on/off operation
and will modulate boiler firing rate to more closely match output to
demand.
High limit operation: If outlet water temperature exceeds target
temperature (or 180°F, whichever is lower), high limit action occurs.
The control module shuts the burner off showing “b 9” followed by
“26” on the display.
DHW operation (if used): The boiler is factory set to immediately
change target outlet water temperature to 180°F on a call for heat
from the DHW aquastat.
Electrical Specifications
Boilers require 120 vac/60 HZ power supply and are not polarity sensitive.
Additional Thermal Overrun Protection: High limit operation shuts
down the burner when the outlet water temperature exceeds the target temperature. However, adverse conditions could cause the water
temperature to rise too quickly and overshoot this temperature. The
boiler control’s advanced technology provides protection in the event
of thermal overrun. Using its electronics, the control provides two
additional levels of overrun protection:
Control specifications
Supply voltage
120 Vac/60 hz
Electrical demand
10 VA
Pre-purge timing
10 Seconds
Post-purge timing
15 Seconds
Min. off time, space heating
10.2 Seconds
Pump on after space htg.
0 Minutes
Min. off time, DHW
10.2 Seconds
Pump on after DHW
30.6 Seconds
Line voltage fuse, F1
5 Amp fast-blow
Low voltage fuse, F3
4 Amp slow-blow
•Level 1: Indication would occur if supply water temperature reached 183°F. The control would display a soft lockout code (“b 9” followed by “18” if on the supply or “19” if
on the return). The control would not operate the burner
again until the water temperature dropped 9°F below target
temperature.
•Level 2: Lockout would occur if supply water temperature
reached 200°F or if the return water reached 193°F. The
control would enter hard lockout and display an error code
(“E” followed by “18” if on the supply or “19” if on the
return).
Boiler Circulator
The circulator has sufficient head to handle the boiler pressure drop
plus reasonable pressure drop in the connecting piping. See the
separate Installation Manual (P/N# 240006103) for piping and flow
rate information.
NOTICE
NOTE: Hard lockout requires manually pressing the display
panel reset button to restart operation. Service technician must
troubleshoot the cause of the problem and correct it before placing the boiler back in operation.
The boiler control’s internal relay contact is suitable for handling only
the boiler circulator provided. Do not wire additional pumps in parallel with the boiler circulator. To operate a system circulator when the
boiler circulator is running, see the section on “Electrical Wiring” in
the Installation Manual for wiring required.
Low Water Protection
Boiler Temperature Regulation
1. This boiler comes factory equipped with a manual reset low
water cutoff. In addition, the boiler control uses temperatures
sensed at both supply and return areas of the heat exchanger. If
the flow rate is too low (temperature difference too high) or either temperature is too high, the control shuts the boiler down.
This ensures boiler shutdown in the event of low water or low
flow conditions.
Operating temperature (target): The boiler control senses outlet water temperature and regulates the boiler firing rate to achieve a target
temperature, set by installer with Parameter 4. Temperature can be
set between 120°F and 194°F.
1. Space heating: Target temperature is fixed (equal to Parameter
4) when outdoor reset is not installed or calculated as described
under “Outdoor Reset Operation” when outdoor sensor is connected.
2. Some codes and jurisdictions may accept these integral features
of the control in lieu of requiring an additional limit control
or low water cutoff. Consult your local jurisdiction for more
information on low water cutoff requirements.
2. Exception: See explanation of “Supply Temperature Boost.”
3. DHW heating: Target temperature is determined by adding
Parameter 1 to Parameter 33 (default 150°F and 30°F). Do not
change Parameter 1 from the factory default setting of 150°F
Freeze Protection
4
Do not install the boiler in a room likely to freeze.
II - Operating Information
Reset curve: The graph below shows how the boiler control calculates target temperature.
NOTICE
Indicates information NOTE: The following integral feature of
the boiler control provides some protection for the boiler only,
not for the system. which should be followed to ensure proper
installation and operation.
•For outdoor temperature at or below 0°F, the target temperature equals Parameter 4 and never higher.
•For outdoor temperature above 0°F, the target temperature is reduced on a curve that would result in 60°F supply
temperature at 70°F outdoor temperature.
The control module provides freeze-up protection as follows when
the boiler water temperature drops below 45° F:
Summer/winter switch option: Install a summer/winter switch, if
desired, to disable the boiler (space heating) circulator during nonheating months. Connect switch across the outdoor sensor terminals. When switch closes, the boiler circulator is disabled and the
boiler operates only on call for DHW heating.
•Below 45° F, the boiler circulator operates constantly.
•Below 37° F, the boiler turns on at low fire.
•Boiler and circulator turn off if boiler water temperature
rises above 50° F.
Reset Curve Calculations
CAUTION
210
Parameter 4 = 190°F
190
Target Outlet Temperature, °F
!
Reset Curve Calculations
Outdoor Reset Target Temperature
This feature of the boiler control does not eliminate the possibility of freezing. The installation must still use recognized design,
installation and maintenance practice to prevent freeze potential
for the boiler and system.
Supply Temperature Boost
In outdoor reset operation (factory supplied, field installed outdoor
sensor connected), the boiler control automatically increases the
target outlet water temperature if a call for heat exceeds 10 minutes.
At each 10 minutes of a continuous call for heat, the control module
increases the target temperature by 18°F. The module will continue
increasing target temperature until it reaches the value set in Parameter 4.
Parameter 4 = 170°F
170
160
Parameter 4 = 150°F
150
130
120
110
90
70
50
When the call for heat ends while target temperature is “boosted,”
the target temperature drops about 2°F for each minute the thermostat is open.
70
60
50
40
30
20
10
0
-10
-20
Outside Temperature, °F
Default Reset Curve
Purpose of “Boosting”: If the target temperature happens to be
too low, the control “boosts” the target temperature until the supply
water meets the system’s needs.
Default Reset Curve
Outdoor Reset Target Temperature
210
190
Target Outlet Temperature, °F
Outdoor Reset Operation (if used)
Target temperature with outdoor reset: All boilers are
shipped with an outdoor temperature sensor. When this sensor is
installed (low voltage terminal strip terminals A1 and A2), the boiler
control regulates target outlet water temperature based on outside
temperature. Set the temperature curve by setting Parameter 4 to:
•ODT (outdoor design temperature for the area).
•For ODT of 0°F or lower, set Parameter 4 to the desired
supply temperature at the ODT.
Parameter 4 = 180°F
180
170
160
150
130
120
110
90
70
•For ODT above 0°F, set Parameter 4 to the desired system
temperature when outdoor temperature is 0°F.
Parameter 6 = 0°F
Parameter 7 = 60°F
50
70
60
50
40
30
20
10
Outside Temperature, °F
5
0
-10
-20
Ii - operating information
circulator activated the DHW circulator and immediately sets target
outlet water temperature to 180°F. This provides automatic priority
heat allocation to the indirect water heater for maximum response
and recovery. The DHW circulator continues for 30.6 seconds after
the heating cycle to deliver the most possible heat.
DHW Operation (if used)
The boiler control allows connection of a DHW aquastat to low
voltage terminal strip terminals DHW T1 and DHW T2. When
the DHW aquastat calls for heat, the module shuts down the boiler
III - Modulating Control Features
Boiler Control Design
Domestic Hot Water (DHW): When used in conjunction with an
indirect hot water heater this boiler has the capability to provide domestic hot water. An on/off dry contact aquastat is used to activate
the call for domestic hot water.
The integrated modulating boiler control is designed for central
heating (CH) hot water boilers with modulating fan and gas-air
control. Options for domestic hot water (DHW) and outdoor reset
are available. Modulation is based upon data relayed to the control
by specific temperature sensors. To ignite the burner, a direct spark
igniter (DSI) is used.
Outdoor Reset: This control has the ability to sense outside air
temperature using a factory supplied, field installed sensor. The controller detects the presence of the sensor and acts according to the
parameters programmed into the controller.
The modulating boiler control is intended for use in combination
with a display/user interface unit for both information and operation
purposes. The control is designed for installation with a conventional
on/off dry contact room thermostat. The control is able to provide
hot water and outdoor reset functions.
Display/User Interface
By means of the display/user interface, the installer and home owner
can scroll through the control settings and customize the boiler to
the heat delivery system used in the location of installation. See the
“User Interface Quick Reference” in Section X of this manual for
more information on using and programming the boiler control.
Main Controller Functions
Central Heat (CH): The control uses sensors on the supply water,
return water and outside air to determine the heat load of the heating system. This results in the boiler supplying just enough heat to
satisfy the demand which results in fewer overshoots and less short
cycling than a conventional on/off boiler.
IV - Boiler Startup
B. Press the “Step” button until the first digit of the display
shows “3.”
C. The last digit must show a “1.” If any other number
displays, press the “+” button until a “1” shows in the
right-hand digit, then press the “Store” button to save this
setting.
NOTICE
NOTE: Instructions in this manual are based on factory default
parameter settings.
2. Set space heating target temperature
Startup
1. Start the boiler only after completing all instructions in the
Installation Manual.
A. Press the “Step” button until the first digit of the display
shows “4.” The last three digits will show the outlet water
temperature setting.
B. Press the “+” or “-” buttons to change the setting to the
desired outlet water temperature. The factory default setting is 180°F.
2. To start the boiler, follow the “Operating Instructions” in this
manual.
3. Once the boiler has started and is operating, continue the
startup procedure by performing all of the following steps to set
and verify operation of the controls.
•Outdoor sensor installed: Setting is the target temperature
for outdoor temperature at or below the factory setting
(32°F). At higher outside temperatures, the control module
calculates the target temperature.
Set Space Heating Operation
1. Verify Space Heating Mode
•When a summer/winter switch is used, closing the switch
will disable the boiler (space heating) circulator during
summer operation.
A. Press the “Mode” button until the display shows [PARA].
This is the parameter mode.
6
IV - boiler startup
•Outdoor sensor not installed: Setting is the target temperature at all times.
•If burner flame proves within 4.5 seconds, burner continues to fire. Burner will fire at startup rate for about 10
seconds to allow flame to stabilize.
C. Press the “Store” button to save the setting.
•If burner flame does not prove within 4.5 seconds, control
module attempts ignition sequence again. Flame must
prove within 6 attempts or control will lockout (display will
show [E 02]).
Check DHW Operation Setup
NOTICE
NOTE: If the control is already in parameter mode , skip step 1
(below) and proceed to step 2.
•Verify flame failure operation by closing boiler manual
gas cock to prevent gas flow. Open manual gas valve after
testing.
1. Press the “Mode” button until the display shows [PARA] (parameter mode).
•[3180] Burner on, space heating. Once flame is proven and
stable, the burner turns down to low fire for approximately
2 minutes.
2. Press the “Step” button until the first digit of the display shows
a “2.”
•After this low fire period, the burner is allowed to modulate. Firing rate depends on actual outlet water temperature
versus target temperature.
3. The last digit must show a “1.” If any other number displays,
press the “+” button until a “1” shows in the right-hand digit,
then press the “Store” button to save this setting.
5. Allow boiler to bring water temperature to target temperature.
4. The control module turns on the DHW circulator when the indirect water heater operating control closes. The control module
shuts off the boiler circulator (stops space heating) during calls
for DHW heating.
•[6180] Target temperature reached. The burner will shut
down. The blower will run in post-purge (see below), then
turn off. Boiler circulator continues to run as long as there
is a call for heat.
Verify Operation – Space Heating
6. Lower room thermostat to stop call for heat.
NOTICE
•[1180] Post-purge. When room thermostat is satisfied (call
for heat ended), burner turns off. Blower will continue for
15-second post-purge, then turn off. If another call for heat
occurs, boiler will remain off for ten seconds before starting again, and the display will show [6180].
NOTE: Information below presented in brackets “[ ]” represents
the actual display on the boiler control panel with the first digit
indicating boiler status and the last three digits showing the
measured boiler water temperature. (Ex.- [A180] indicates a
status of “A” and a boiler water temperature of 180°F.)
•[0180] No call for heat. Boiler is now in standby mode
(waiting for heat call).
7. Repeat steps 1-6 several times to verify operation.
1. Turn down DHW aquastat on DHW tank (if used). If necessary, turn off power and remove one of the DHW aquastat wires
to ensure boiler will not receive a DHW heat call.
8. Return the room thermostat to normal setting.
Verify Operation – DHW
2. Turn off power to boiler at service switch.
1. If necessary, reconnect DHW aquastat wiring to boiler.
3. Wait a few seconds, then turn on power to boiler.
2. Turn off power to boiler at service switch.
•[180] Self-check on power-up for a few seconds.
3. Wait a few seconds, then turn on power to boiler.
[A150] Self-check on power-up for a few seconds.
[0150] No call for heat.
4. Raise DHW aquastat above tank temperature to call for heat.
•[0180] No call for heat.
4. Raise room thermostat to call for heat.
•[5180] Blower/boiler circulator on. Blower and boiler circulator energize and control checks for air flow.
•[5150] Blower/DHW circulator on. Blower and DHW
circulator energize and control checks for air flow.
•[1180] Pre-purge. Blower speed will increase to ignition
speed. The blower will run in pre-purge for 10 seconds.
•[1150] Pre-purge. Blower speed will increase to ignition
speed. The blower will run in pre-purge for 10 seconds.
•[2180] Ignition. After pre-purge, the control module opens
the gas valve and starts ignition spark.
7
IV - boiler startup
•[0150] No call for heat. Boiler is now in standby mode
(waiting for heat call).
•[2150] Ignition. After pre-purge, the control module opens
the gas valve and starts ignition spark.
7. Repeat steps 1-6 several times to verify operation.
•If burner flame proves within 4.5 seconds, burner continues to fire. Burner will fire at startup rate for about 10
seconds to allow flame to stabilize.
8. Return the DHW aquastat to normal setting.
Operating Information
•If burner flame does not prove within 4.5 seconds, control
module attempts ignition sequence again. Flame must
prove within 5 attempts or control will lockout (display will
show [E 02]).
1. To check operating conditions (Ex - actual or target temperature), see “User Interface Quick Reference” in Section X of this
manual for an explanation of the boiler control’s “Information”
mode.
•Verify flame failure operation by closing boiler manual gas
valve to prevent gas flow. Open gas valve after testing.
2. During normal operation (no shutdown or lockout), the right 3
display digits show actual boiler outlet water temperature.
•[4150] Burner on, DHW. Once flame is proven and stable,
the burner is allowed to modulate. Firing rate depends on
actual outlet water temperature versus target temperature.
Perform Check-out Procedures
Complete the “Checkout Procedures and Adjustments” as indicated
in Section VI of this manual.
5. Allow boiler to bring water temperature to target temperature.
•[6150] Target temperature reached. The burner will shut
down. The blower will run in post-purge (see below), then
turn off. DHW circulator continues to run as long as there
is a call for DHW heating.
WARNING
!
6. Lower DHW aquastat to stop call for heat.
•[1150] Post-purge. When room thermostat is satisfied (call
for heat ended), burner turns off. Blower will continue for
15 second post-purge, then turn off. If another DHW heat
call occurs, boiler will begin heating cycle after 10 second
delay. If a CH call for heat occurs after a DHW demand,
the heating cycle will begin after a 30 second delay.
•[8150] DHW circulator run-on. The DHW circulator continues to run for 30 seconds.
8
Replace boiler front jacket panel after performing any service to
the boiler.
V - Checkout Procedures and Adjustments
Verify Sequence Of Operation
A detailed sequence of operation containing potential faults can be
found in Sections VI, “Detailed Sequence of Operation.” Refer to this
section and Section VII, “Service Hints,” for more information.
If the boiler is equipped with any additional safety controls, test for
operation as outlined by the control manufacturer. Burner should be
operating and should go off when controls are tested. When safety
controls are restored, burner should reignite.
Inspect Venting And Air Intake
Set Field Installed Thermostat
Operate the boiler and verify that all vent/air intake connections are
gastight and watertight. Repair any leaks immediately.
Heat Anticipator (if used)
Test Ignition System Safety Shutoff Device
For a single thermostat connected to the T-T screw terminals on the
low voltage terminal strip on the control board of the boiler, the heat
anticipator should be set at 0.1 amps. For other wiring configurations, refer to the instructions provided by the thermostat manufacturer regarding heat anticipator adjustment. Cycle boiler with
thermostat. Raise the thermostat to the highest setting and verify
boiler goes through normal start up cycle. Lower thermostat to lowest setting and verify boiler goes off.
1. Remove front panel from appliance.
Boiler Adjustment
Inspect condensate drain and
System Piping
Verify that condensate flows freely and all connections are watertight. Repair any leaks immediately.
2. Turn off manual gas ball valve.
NOTICE
3. Set thermostat for a call for heat.
Indicates information which should be followed to ensure
proper installation. NOTE: It is important that this appliance
operate as specified in the table below. The following steps can be
used to verify that the appliance is operating in this range. n and
operation.
4. Boiler begins normal sequence of operation.
5. After approximately 30 seconds of pre-purge the appliance will
attempt to light.
6. After 4 seconds the gas valve closes and the control retries 5
time, before entering lockout mode.
Check incoming gas pressure to the appliance using a pressure gauge
with a resolution of 0.1” w.c. or better and a range from 0” to at least
14” w.c. Close the gas shutoff inside the boiler jacket. Locate the inlet
pressure tap on the gas valve (see Figure 1) and open the inlet pressure tap screw ½ turn. Connect the positive side of the gauge to the
inlet pressure tap, then open the gas shutoff. The gas pressure at high
fire should read between 4” and 10” w.c. for natural gas and between
10” and 14” w.c. for LP gas.
7. To reset the control, follow the instructions in Section IV of this
manual, “Putting The Boiler In Operation.”
8. Return thermostat to previous setting.
Test And Adjust High Limit Control
While burner is operating, adjust setting on high limit control below
actual boiler water temperature. Burner should go off while circulator continues to operate. Raise limit setting above boiler water
temperature and burner should reignite after pre purge and igniter
warm-up period. Set the high limit control to at least 10°F above
parameter 4 setting as described in the separate “Parameter Guide”
(P/N# 240006105). Maximum high limit setting is 200°F. Minimum
high limit setting is 100°F.
Figure 1 - Gas Valve
Test Low Water Cut Off
1. Disconnect the wire from the LWCO sensor probe.
2. Set thermostat for call for heat.
3. Boiler should not begin normal sequence of operation.
4. Attach wire to the sensor probe.
5. Return thermostat to previous setting.
6. Drill a ½” hole in the plastic CPVC vent pipe or exhaust tee,
just large enough to allow access for the sample probe of your
Test Other Field Installed Safety Controls (if used)
9
v - checkout procedures and adjustments
combustion analyzer.
7. Turn the thermostat to the closed position so the appliance is
activated.
8. Set appliance to high fire mode as described in the “User Interface Quick Reference” section of this manual and allow it to run
for approximately 5 minutes.
9. Insert the sample probe of your combustion analyzer into the
hole you drilled in Step 2 about halfway into the exhaust gas
stream. Take a flue gas reading and observe the % CO2 and CO
values. Adjust the throttle screw until the correct readings are
reached. Turning the throttle screw clockwise decreases the rate
and the CO2 value. Turning the throttle screw counter clockwise increases the rate and the CO2 value. Allow the appliance
to stabilize for approximately one minute after adjusting the
throttle screw before you take a reading with your combustion
analyzer.
NOTICE
IMPORTANT: Under all conditions CO levels should not exceed
80 ppm.
10. Set appliance to low fire mode as described in the “User Interface Quick Reference” section of this manual and check CO2
level as stated in Step 5. Low fire and high fire values should be
approximately the same.
11. After adjustments are made stop the appliance, disconnect the
pressure gauge, tighten the inlet pressure tap on the gas valve,
remove the CO2 meter from the CPVC pipe, and seal the hole
with a ¼” NPT black iron plug. Use thread sealing compound
or teflon tape to ensure a proper seal.
12. Return the thermostat switch to its original position.
NOTICE
Installers: Complete and sign the “Installation and Checkout
Certificate” on the last page of this manual.
5. Turn off all other gas appliances, extinguishing standing pilots
where applicable.
6. At the gas meter, measure the time in seconds required to use
one cubic foot of gas.
NOTICE
NOTE: Boiler must be in high fire mode for this operation. See
the “User Interface Quick Reference” in this manual for more
information on putting the boiler in high fire mode.
7. Calculate the BTUH Input Rate as follows:
Btuh input rate =
3600 x heating value from Step 3
16 +/- 2 seconds
8. The measured input rate will vary with vent length, gas calorific
content, altitude and ambient temperature. The boiler should be
set up with the combustion specifications in the “Boiler Adjustment” section.
Determine Lp Gas Input Rate
LP gas input rate is determined by measuring the C02 produced during combustion. This value should be set according to the guidelines
table on the following page.
Measure Flame Sense
Flame sense can be an indicator of issues with air intake venting,
exhaust venting, burner and ignitor condition and supply gas piping
pressure. Using a multi meter capable of reading 0-20 VDC, attach
one lead to the “F” terminal on the low voltage terminal block on
the boiler control, and the other to any ground surface on the boiler.
(See Figure 2). The flame sense voltage must be in accordance with
the values listed in the Flame Signal Guidelines chart later in this
manual.
Figure 2 Multimeter
Measure The Natural gas input rate
Correct input rate is essential for proper and efficient operation of
the burner and boiler.
1. Determine the elevation at the installation site.
2. See Table 2 in Section IV of the separate “Installation Manual”
(P/N# 240006103) to determine the correct approximate input
rate for the local elevation.
3. Obtain the yearly average heating value of the local gas utility.
At sea level elevation, it should be approximately 1000 BTU per
standard cubic foot.
4. Operate boiler for 5 minutes.
10
v - checkout procedures and adjustments
Pressure Guidelines
Fan Speed
Minimum RPM
Maximum RPM
Fuel
Natural Gas
LP
Natural Gas
LP
Gas Line Inlet
N/A
N/A
At least 4” WC
At least 10” WC
Pressure
Differential Pres0.3” WC
2.0” WC
sure
Note: Differential pressure values listed for comparison only. These values will change with vent length
and altitude of installation.
Combustion Guidelines
Natural Gas
Outside
Temperature
70°F and up
21°C and up
30°F to 70°F
-1°C to 21°C
30°F and below
-1°C and below
LP Gas
%CO2
%O2
CO
%CO2
%O2
CO
9.6% to
10%
3.9% to
3.2%
Less than
80 PPM
11.1% to
11.5%
4.1% to
3.4%
Less than
80 PPM
9.3% to
9.6%
4.4% to
3.9%
Less than
80 PPM
10.8% to
11.1%
4.5% to
4.1%
Less than
80 PPM
9.0% to
9.3%
5.0% to
4.4%
Less than
80 PPM
10.5% to
10.8%
4.9% to
4.5%
Less than
80 PPM
Flame Signal Guidelines
Fan Speed
Flame Signal
Minimum RPM
Greater than 3.0 VDC
Maximum RPM
N/A
11
VI - Detailed Sequence of Operation
12
VII- Service Hints
WARNING
!
Do not attempt to modify the characteristics of this boiler in any
way!! Fire, explosion, or risk of shock hazard may cause property
damage, severe injury, or death.
Troubleshooting Tools
Have the following tools available prior to troubleshooting your
boiler:
•Voltmeter that can check 120 VAC, 24 VAC, and 12 VDC
•Continuity Tester
•Contact Thermometer
•Inclined Manometer or Pressure Gauge with 0-6.0” range
(0.01” scale) for measuring suction pressures at pressure
switch
NOTICE
Important
If any component does not function properly, make sure it is
correctly installed and wired before replacing it.
Static electricity discharge can damage the integrated modulating boiler control (IMBC). Touch metal surface to discharge
static electricity before touching control.
The boiler control cannot be repaired. If it malfunctions it must
be replaced.
Only trained, experienced service technicians should service
the boiler control systems. After troubleshooting, follow the
“Detailed Sequence of Operation” in this manual for a normal
light off procedure.
All controls are factory tested in the assembly process and a
defective control is generally the least likely cause. If you suspect
you have a defective boiler control, read through the “Troubleshooting” section of this manual before you replace it.
It is extremely unlikely that the two consecutive controls are
defective. If it seems to be happening, chances are that either
there is nothing wrong with the control or it is being damaged
by some other problem (for example, an electrical short burning
out a transformer).
•U-Tube Manometer or Differential Pressure Gauge with
0-14” range (0.1” scale) for measuring inlet and manifold
gas pressures
Initial Service Checks
Prior to troubleshooting:
1. Make sure that circuit breaker is on or fuse is okay at electrical
panel.
2. Make sure that service switch is on.
3. Check for 120 VAC (minimum 102 VAC to maximum 132
VAC) to boiler.
4. Make sure thermostat is calling for heat and contacts (including appropriate zone controls) are closed. Check for 24 VAC
between thermostat wire nuts and ground.
5. Make sure all external limit controls are either installed (and
closed) or temporarily jumpered for testing.
6. Make sure that gas is on at the gas meter, at all appropriate
manual shutoff valves, and at the gas control valve. Gas pressures should be a maximum of 10” w.c. (natural gas) or 14” w.c.
(for LP gas) with no flow (lockup) or with boiler on and a minimum of 5” w.c. with gas flowing (verify during boiler startup
with boiler at high fire).
7. Check that wire connectors at the boiler control and at the
originating control are securely plugged in or connected.
8. Check that all hoses are securely connected and are not plugged
in or damaged.
13
VIII - Troubleshooting
Checking the Differential Air Pressure
WARNING
!
Electrical shock may cause serious injury or death. The following
procedures may expose you to dangerous line voltage so use caution to avoid touching live electrical contacts. All service must be
performed by a trained, experienced service technician.
WARNING
!
Should overheating occur or the gas supply fail to shut off, do
not turn off or disconnect the electrical supply to the pump.
Instead, shut off the gas at a location external to the appliance
Do not use the boiler if any part of the gas control system has
been underwater. A qualified service technician should inspect
the boiler and replace any part of the control system and any gas
control which has been underwater.
Use only your hand to turn the gas control knob. Never use
tools. If the knob will not turn by hand, don’t try to repair it.
Force or attempted repair may result in a fire or explosion.
CAUTION
!
WHAT TO DO IF YOU SMELL GAS
Do not try to light any appliance.
Do not use any electrical appliance.
Do not touch any electrical switches; do not use any phones in
your building.
Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions. If you cannot reach your gas
supplier, call the fire department.
Boiler Status
Diff. Pressure
Not Running
0”
Running with Blockage
Greater Than or Equal
To Setpoints
3.5”
Open
0.14”
Closed
Min. Fire: 0.3”
3.5”
Closed
Max. Fire: 2”
0.14”
Closed
Running w/out Blockage
(approx.)
Differential Air Pressure
Switch Contacts
3.5”
Closed
0.14”
Open
If manometer readings do not correspond to the chart above,
check for possible causes:
• Blockage or moisture in suction lines to switch.
The differential air pressure switch is a safety device which will
prevent the boiler from firing if there is an air intake, boiler heat
exchanger or vent blockage.
• Blockage in air intake or vent pipes.
To check the differential air pressure:
• Undersized air intake or vent pipes.
1. Turn off service switch or lower thermostat setting.
• Loose blower wheel on motor shaft.
2. Remove vinyl caps from tee.
• Incorrect pressure switch or pressure switch setpoint
When pressure reading is proper and the pressure switch is operating properly, remove testing lines and reinstall vinyl caps to Tee
and 3-way connector.
3. Install testing lines as shown to inclined manometer or differential pressure gauge with the ability to read 0.01” increments
to at least 6.0” w.c.
4. Turn on service switch and set thermostat to call for heat.
14
VIII - troubleshooting
WARNING
WARNING
!
Label all wires prior to disconnection when servicing controls.
Wiring errors can cause improper and dangerous operation.
Always disconnect power to boiler before servicing. Failure to
comply could result in severe personal injury, death or substantial property damage. Never jumper (bypass) any device except
for momentary testing as outlined on the following pages of this
manual. Severe personal injury, death or substantial property
damage can result.
!
Do not jumper fuse or replace with any fuse except as specified.
Failure to comply could result in severe personal injury, death or
substantial property damage.
7. Install control module cover and jacket top front cover after
fuse inspection.
8. Restore power to boiler at external line switch and verify boiler
operation after completing boiler service.
Checking temperature sensors
1. The boiler temperature sensors (outdoor, return water, and supply water) are all resistance-type devices.
Control Module Fuses
NOTICE
IMPORTANT: Always check control module fuses before replacing control module or any major components (blower, etc.) If
one of these fuses is blown, it can prevent the control module or
other components from operating.
2. The table below shows the correct resistance value for the sensor at various temperatures.
Temp
°F
Sensor Ohms
Min
Max
Temp
°F
32
34,265
37,871
40
27,834
50
2. Remove jacket front panel.
3. Remove control module cover.
1. Turn OFF power to boiler at external line switch.
4. Inspect fuses F1 and F3 (shown below).
Sensor Ohms
Min
Max
130
3,698
4,088
30,764
140
3,043
3,364
21,630
23,907
150
2,517
2,782
60
16,944
18,727
160
2,091
2,311
70
13,372
14,780
170
1,744
1,928
80
10,629
11,747
180
1,461
1,615
90
8,504
9,399
190
1,229
1,359
100
6,847
7,568
200
1,038
1,147
110
5,545
6,129
210
880
972
120
4,517
4,992
212
851
941
3. Use the resistance values at 32°F, 60°F, 70°F and 212°F to
measure the sensor resistance at known temperatures (ice point,
room temperature and sea level boiling point). For ice point
and boiling point, insert the sensor in water at that temperature.
Use an ohm meter to read resistance value.
4. To check whether the control module is correctly sensing
temperature, you can use a resistance decade box. Connect the
decade box temporarily in place of a sensor and use the control
module “Information” mode to read the temperature.
F1 and F3 Fuses
5. The boiler is shipped with four spare fuses attached to the control module cover.
6. If necessary, replace open fuse (F1 is 115V, 5-amp fast-blow; F3
is 24V, 4-amp slow-blow).
15
VIII - troubleshooting
Boiler Not Firing And:
Check For:
Step
Corrective Actions:
1 NO - Check external line switch and fuse or breaker.
120 vac at terminals L1 and L2 of line
voltage strip?
Determine if the red light on the line voltage monitor is flashing
indication a fault. If there is a fault verify that the input voltage dial is
2
properly set in accordance with the steps in the installation manual. If
the fault does not clear after ten minutes replace the line monitor.
Control display blank
120 vac on both sides of fuse F1? (Turn
OFF external power to boiler before
removing cover.
1
NO - Turn off power to boiler and replace fuse if necessary. Inspect
boiler interior wiring to determine cause of fuse opening.
Wiring correct, in good condition, and
securely attached?
1
Correct if needed. Replace any damaged wiring or components. Replace control module if problem persists.
Room thermostat and DHW aquastat
satisfied?
1
YES - Boiler off, no call for heat. Turn up thermostat or aquastat.
Boiler should start.
Check voltage on both sides of low voltage fuse F3. (Turn OFF external
1 power before removing cover.) If necessary, replace fuse. Determine
reason for fuse failure if possible.
Display first digit shows 0; last digits
show 2 or 3-digit number (boiler
Thermostat or aquastat calling for heat
outlet water temp.)
but boiler not firing.
2
Check/set boiler parameters 2 and 3. Make sure space heat or DHW is
turned on. Turn on if necessary.
Turn off power to boiler. Temporarily jumper low voltage terminal
strip terminals T1 and T2 or DHW T1 and DHW T2. Retry. If boiler
3
operates, check CH and DHW thermostat and wiring. Replace if necessary. Remove temporary jumper(s).
4
Turn off power to boiler. Check wiring against wiring diagram; verify
all wiring in good condition and secure.
5 Replace wire harnesses and retry.
6 Replace control module.
Display first digit shows a number from 1 to 8; last digits show 2 or 3-digit
number (boiler outlet water temp.)
1 Boiler in normal operating mode.
Display flashes “9,” then “b.” Last two digits show code number.
1
16
See User Interface Quick Reference and Soft Lockout Troubleshooting in
this manual for for more information on the soft lockout code.
VIII - troubleshooting
SOFT LOCKOUT (Display flashes “9” and then “b” in first position; last two digits on steady (code))
Code
Reason For Soft Lockout
Corrective Actions (pressing RESET should restart boiler immediately):
WARNING: Electrical shock hazard. Turn off power to boiler when working with wiring or replacing any boiler component.
08
18
19
24
25
0.14” Pressure switch contacts open
1
Check pressure switch for proper operation. Replace pressure switch if moisture has entered
switch. Check venting for blockage. Clear if present.
1
This should only happen when the heat demand is lower than the lowest firing rate of the boiler,
such as operation of a single, small zone. Check system for:
Verify boiler and system are full of water.
Make sure system does not have trapped air.
Inspect and verify system piping and components.
Verify piping agrees with boiler manual recommendations.
2
Use contact thermometer to check outlet water temp. Compare to temp. shown with display in
“INFO” mode (“1” in first digit). Replace return temp. sensor if results are not close. Replace
control module if sensor replacement doesn’t solve problem.
1
Check system for:
• Verify boiler and system are full of water.
• Make sure system does not have trapped air.
• Inspect and verify system piping and components.
• Make sure water flow is not reversed or pipes crossed.
2
Use contact thermometer to check return water temp. Compare to temp. shown with display in
“INFO” mode (“2” in first digit). Replace return temp. sensor if results are not close. Replace
control module if sensor replacement doesn’t solve problem.
1
Verify boiler and system are full of water.
Make sure system does not have trapped air.
Inspect and verify system piping and components.
Make sure water flow is not reversed or pipes crossed.
2
Use contact thermometer to check return water temp. Compare to temp. shown with display in
“INFO” mode (“2” in first digit). Replace return temp. sensor if results are not close. Replace
control module if sensor replacement doesn’t solve problem.
1
This usually indicates flow rate too low. Check system for:
Verify boiler and system are full of water.
Make sure system does not have trapped air.
Inspect and verify system piping and components.
Verify piping agrees with boiler manual recommendations.
2
Verify operation of boiler circulator:
Check voltage at circulator junction box to ensure 120 vac when boiler operates. If no voltage,
check wiring and wiring connections.
High voltage terminal strip terminals 5 and 6 should show 120 vac for space heating; terminals 3
and 4 should show 120 vac for DHW. Replace circulator if powered but not operating.
Replace line voltage wire harness if necessary. Replace control module if wire replacement
doesn’t resolve.
High Limit Operation: Burner off until
outlet water temp. drops below 180 °F
High Limit Operation: Burner off until
return water temp. drops below 190 °F
High Limit Operation: Return temp. is
higher than supply temp.
High limit operation: Outlet water
temp. increased too quickly.
Non-adjustable default setting 9.8°F/sec
1
26
Aquastat contacts open
or
LWCO contacts open
or
3.5” Switch open
Verify proper setting of control.
Water temp too high, wait for temperature to drop below 180 degrees.
2
Check water level in boiler, fill if low.
Press LWCO reset switch on display panel
If problem still exists, check LWCO probe and board according to manufacturer’s instructions. Replace if
necessary.
3
Check pressure switch for proper operation. Replace if moisture has entered switch. Check venting for blockage. Clear if present.
17
VIII - troubleshooting
29 Blower turning when it should be off.
1
Check boiler wiring against wiring diagram. Replace line voltage and low voltage wiring harnesses
if necessary. Replace control module if wire replacement doesn’t resolve.
This usually indicates flow rate too low. Check system for:
Verify boiler and system are full of water.
1 Inspect and verify system piping and components.
Verify piping agrees with boiler manual recommendations.
Make sure system pressure drop is not too high.
30
High limit operation: Temp. rise across
boiler too high.
Verify operation of boiler circulator.
Check voltage at circulator junction box to ensure 120 vac when boiler operates. If no voltage,
check wiring and wiring connections.
2 High voltage terminal strip terminals 5 and 6 should show 120 vac for space heating; terminals 3
and 4 should show 120 vac for DHW. Replace circulator if powered but not operating.
Replace line voltage wire harness if necessary. Replace control module if wire replacement doesn’t
resolve.
Check pressure switches for proper operation. Replace pressure switch if moisture has entered
switch.
61 Pressure switch contacts closed.
1
65 Blower not operating when turned on.
Turn off power to boiler. Remove line voltage connector at blower. Restart boiler and check voltage
across blower plug terminals. If 120 vac is NOT present, inspect wiring and tightness of con1
nections. Replace line voltage wire harness if necessary. Replace control module if wire harness
replacement doesn’t resolve.
2
If 120 vac is present on blower wire harness, replace harness and retry. If problem persists, replace
blower motor.
18
VIII - troubleshooting
HARD LOCKOUT (Display flashes first digit “E” and last two digits (code))
Code
Reason For Hard Lockout
Corrective Actions (pressing RESET should restart boiler immediately):
WARNING: Electrical shock hazard. Turn off power to boiler when working with wiring or replacing any boiler component.
00 Flame detected on startup.
Burner may be operating too hot due to incorrect combustion. Inspect flame during operation
following the procedure in this manual. If flame is acceptable at both high and low fire, go to step
2. If flame is not acceptable:
1
For propane boilers, verify propane orifice is correct and properly installed. Obtain and install
propane orifice if necessary.
For correct orifice propane or natural gas boilers, replace gas valve if burner glows excessively.
Look into the burner inspection window after the boiler shuts down. If flame is still present, gas
2 valve may be leaking. Replace gas valve. BEFORE replacing valve, check gas line pressure coming
to boiler. Pressure must not exceed 13” w.c. or valve damage could occur.
If no ignition spark occurs:
Check ignition electrode cable, electrode connector, and connections.
1
Inspect ignition electrode cable and electrode for insulation damage.
Check ground lead from ground terminal strip to heat exchanger access cover.
02 Ignition failed through 5 attempts.
If spark occurs, but no flame:
Verify manual gas valve in boiler is open.
Verify plastic line from gas valve to air inlet elbow is connected to gas valve and elbow, and line is
unobstructed with no kinks.
Check incoming gas pressure.
Verify gas lines are free of obstruction and purge gas lines of air if necessary.
Verify flue gas vent and air supply piping are correctly installed, in good condition, and free of
obstructions.
2 Check voltage to gas valve (it should be approx. 19-21 VDC (24 vrac) during ignition attempt).
Check gas meter to verify gas flows when gas valve is activated.
Remove and inspect/clean ignition electrode. Clean white oxides if necessary and replace ignition
electrode if in poor condition or unable to be cleaned.
Disconnect gas valve from Venturi. Inspect Venturi gas line to verify there are no obstructions.
Replace gas valve.
Check for possible flue gas recirculation at vent/air terminations or inside boiler housing.
If gas valve is powered, gas flows when activated, and above steps have been verified, replace gas
valve and retry.
Flame occurs but flame signal too low (less than 3 vdc between X1-5 and ground):
Inspect flame at both low and high fire rates. Inspect and clean burner if necessary. Replace burner
if not in good condition.
Check gas flow rate at gas meter with boiler at high fire. If input is not within about 10% of boiler
rating, replace gas valve. (Length of the vent/air piping will affect boiler firing rate, with longer
3
piping causing lower inputs.)
Check ground wire and connections from ground terminal screw to X1-6 terminal on wiring harness. Use ground continuity meter to verify good ground path.
Follow procedure to inspect and clean ignition electrode. Replace ignition electrode if necessary.
If above does not correct problem, replace control module.
03 Gas Valve Disconnected.
1 Verify gas valve connection.
04 Voltage lost after lockout occurred.
1
Control module will only restart with manual reset, even after power loss (but the error code
information is lost).
05
06
07
Internal control failure.
1 Reset control and retry. If problem persists, replace control module.
08
19
VIII - troubleshooting
HARD LOCKOUT (Display flashes first digit “E” and last two digits (code))
Code
Reason For Hard Lockout
Corrective Actions (pressing RESET should restart boiler immediately):
WARNING: Electrical shock hazard. Turn off power to boiler when working with wiring or replacing any boiler component.
09
11
Internal control failure.
1 Reset control and retry. If problem persists, replace control module.
1 Determine reason for limit action and correct. Check for air trapped at top of casting.
12 Casting temperature switch opened.
13 - 17 Internal control failure.
18
Thermal Overrun Condition: Outlet
water temp. above 200 °F
If limits are closed, check wiring and connections. Apply a temporary jumper across terminals 6 and 8 and check operation. If problem persists, check boiler internal wiring. Replace
2
low voltage harness if necessary. Replace control module if harness replacement doesn’t
resolve.
1 Reset control and retry. If problem persists, replace control module.
Check system for:
Verify boiler and system are full of water.
1 Make sure system does not have trapped air.
Inspect and verify system piping and components.
Make sure water flow is not reversed or pipes crossed.
Use contact thermometer to check outlet water temp. Compare to temp. shown with display
2 in “INFO” mode (“1” in first digit). Replace return temp. sensor if results are not close. Replace control module if sensor replacement doesn’t solve problem.
Thermal Overrun Condition: Return
19
water temp. above 190 °F
28 Blower not running.
1 See Code 18, Corrective Action#1 (above).
Use contact thermometer to check return water temp. Compare to temp. shown with display
2 in “INFO” mode (“2” in first digit). Replace return temp. sensor if results are not close. Replace control module if sensor replacement doesn’t solve problem.
Turn off power to boiler. Remove line voltage connector at blower. Restart boiler and check
voltage across blower plug terminals. If 120 vac is NOT present, inspect wiring and tightness
1
of connections. Replace line voltage wire harness if necessary. Replace control module if wire
harness replacement doesn’t resolve.
2
If 120 vac is present on blower wire harness, replace harness and retry. If problem persists,
replace blower motor.
29 Blower signal not 0 when it should be.
1
Inspect wiring and connections. If wiring is correct, replace blower assembly. If blower assembly replacement is unsuccessful, replace control module.
Temp difference between supply & return,
indicated by blocking code b30, was too
30
large for 20 successive times. Non adjustable default Max Delta set to 100°F
1 Inspect supply & return water sensors for proper resistance.
2
Inspect piping for proper configuration. For example, when used in a radiant heating application.
31 Outlet water temp. short circuit.
Inspect outlet water temp. sensor and wiring. Replace sensor if wiring correct and in good
1 condition. Replace low voltage wiring harness if problem persists. Replace control module if
harness replacement doesn’t resolve.
32 Return water temp. short circuit.
Inspect return water temp. sensor and wiring. Replace sensor if wiring correct and in good
1 condition. Replace low voltage wiring harness if problem persists. Replace control module if
harness replacement doesn’t resolve.
36 Supply water temp. sensor open circuit.
1 See Corrective Action# 1 under Code 31 (above)
37 Return water temp. sensor open circuit.
1 See Corrective Action# 1 under Code 32 (above)
44
60 Internal control failure.
1 Rest control and retry. If problem persists, replace control module.
61
65
Blower signal too low (not enough driving
Inspect wiring and connections. If wiring is correct, replace blower assembly. If blower as1
force).
sembly replacement is unsuccessful, replace control module.
20
IX - User Interface Quick Reference
STANDBY MODE - KEY FUNCTIONS AND DISPLAY
When boiler is powered on, the display will always show a single character (which represents the boiler’s current operating sequence) followed by the
measured outlet water temperature during self-test.
When entering Standby Mode, user interface display briefly shows Stby
Stby
then displays Sequence and Measured or Target Outlet Temperature.
0 180
Press and Hold Key(s) in BLACK (1)
Duration
Result
Display
Tap
Outlet water target temperature. (Display shows “c” and outlet water target
temp.) (2)
Hold
Turn space heating OFF/ON. (Display shows “c” and outlet water temp. or
OFF.)
Tap
Show factory setting for DHW. (Make sure to adjust desired water temperature for DHW on the DHW tank aquastat.)
Hold
Turn DHW OFF/ON. (Display shows “d” and DHW factory setting or OFF.)
[MODE] [STEP] [STORE] [+] [-]
Hold
Set burner to high fire. (Display shows “H” and measured outlet water temp.)
H 180
[MODE] [STEP] [STORE] [+] [-]
Hold
Set burner to low fire. (Display shows “L” and measured outlet water temp.)
L 180
[MODE] [STEP] [STORE] [+] [-]
Hold
Deactivate forced high/low firing. (Display shows sequence and measured
outlet water temp.)
0 180
[MODE] [STEP] [STORE] [+] [-]
Tap
Change to next mode. (Para)
Para
[MODE] [STEP] [STORE] [+] [-]
[MODE] [STEP] [STORE] [+] [-]
c 190
d 140
Where two keys are shown pressed at the same time, you must press the keys together. A slight delay in pressing one of the keys may cause a different result.
Outlet water “target temperature” means:
Outdoor sensor not connected - Target is fixed setpoint temp. Control attempts to maintain boiler outlet water temperature to setpoint.
Outdoor sensor connected - Target is temperature calculated by control module based on outside air temperature.
(1)
(2)
21
IX - user interface quick reference
STANDBY MODE - BOILER SEQUENCE DISPLAY
After display shows Stby for a brief period, the first character shows boiler status, followed by boiler outlet water temp. If the burner is being held off due to
a soft lockout, the display alternates between showing “9” followed by boiler outlet water temp. and “b” followed by the two-digit codes below. Soft lockout
means the boiler will start again automatically if the condition is corrected or timed out.
Press [RESET] button to restart boiler without waiting for timeouts below.
First Other
Digit Digits
Boiler Status
Standby - no call for heat
1
Pre-purge (10 seconds) or Post-purge (15
seconds)
3
4
5
6
7
8
H
L
Ignition
Burner on for CH heating
Burner on for DHW heating
Checking airflow before pre-purge
Burner off because temperature setting has
been reached
Pump on after CH heating cycle for run-on of
10 seconds
Pump on after DHW heating cycle for run-on
of 30 seconds
Burner on, running in high fire mode (manually set for test)
Burner on, running in low fire mode (manually set for test)
_18
Outlet temp. too high (over 203°F). Burner off until outlet water temp.
drops 9°F below target temp.
_19
Return temp. too high (over 203°F). Burner off until both outlet and
return water temp. drops 9°F below target temp.
_24 Return temp. higher than supply temp. Burner off waiting for correction.
“9” alternating with “b”
2
Actual (measured) outlet water temperature
0
First Code Boiler is in soft lockout when “9” or “b” shown. Reason for
Digit
# boiler soft lockout is:
_25
Outlet water temp. rose too quickly. Burner off 10 min. (burner recycles,
increasing wait 1 min. each attempt to max. 15 min.)
_26
External limit open, LWCO tripped or 3.5” press switch open on limit
wired in soft lockout (auto reset) circuit. Burner off for 2½ minutes.
_29
Blower signal not 0 when it should be. Burner off until signal condition
terminates.
Temp. rise across boiler more than 100°F. Burner off for 2½ minute wait
_30 (plus 1 minute for each failed attempt, up to max. of 22 minutes each
time).
_61 Air pressure switch does not open.
_65 Waiting for blower to start.
22
IX - user interface quick reference
PARAMETER MODE
Press [MODE] button 1 time from Standby Mode.
Display shows Para until a key is pressed
Para
then displays Parameter and Current Status.
Press and Hold Key(s) in BLACK (1)
Duration
[MODE] [STEP] [STORE] [+] [-]
Tap
Step to next parameter (continue tapping Step
to
change to 1, 2, 3, or 4)
Tap
Increase setting
Hold
FAST increase setting
Tap
Decrease setting
Hold
FAST Decrease setting
[MODE] [STEP] [STORE] [+] [-]
Tap
Store current setting (tap this key after setting
the parameter as desired)
[MODE] [STEP] [STORE] [+] [-]
Tap
Next mode (info)
[MODE] [STEP] [STORE] [+] [-]
[MODE] [STEP] [STORE] [+] [-]
DHW Setting: Left digit shows
“1” and right digit shows “140.”
DO NOT change this setting.
Performance could be unreliable. Set DHW tank temp. on
DHW aquastat.
1 180
Result
DHW Setup: Left digit shows “2” and
right digit should show “01.” DO NOT
change this setting. DHW performance could be unreliable or unsafe.
Display
DHW Setting
1 140
DHW Setup
2
01
Space Heating Setup
3
01
Outlet Temperature
4 190
(See details below)
Info
Space Heating (SH) Setup:
Left digit shows “3” and
right digit should show “01.”
DO NOT change this setting
as it might affect performance of your boiler.
SH Temperature: Left digit shows “4” and right
three digits show target outlet water temp. (at
32°F outside if outdoor sensor is used). Adjust
to desired settings with + and - keys.
(1) After the [STORE] button is pressed, the set value will flash twice to confirm the change. Change will take effect after you leave Parameter Mode.
23
IX - user interface quick reference
INFORMATION MODE
Press [MODE] button 2 times from Standby Mode.
Display shows Info until a key is pressed
Info
Then displays Parameter, Flashing Dot, and Current Status.
Press and Hold Key(s) in BLACK (1)
Duration
Result
[MODE] [STEP] [STORE] [+] [-]
Tap
Step to next parameter
1.190
Display
Measured outlet water temperature
(First digit shows 1 and dot flashes) (1)
1.180
Return water temperature
(First digit shows 2 and dot flashes) (1)
2.150
This function not used
(First digit shows 3 and dot flashes) (2)
3.-18
(1) Digits after flashing dot show measured outlet temperature.
(2) Digits after flashing dot show -18.
(3) Digits after flashing dot show outside temperature.
(4) Digits after flashing dot show target outlet temperature.
(5) Digits after flashing dot show rate of change in °F per second.
(6) Digits after flashing dot show -32.
Outside temperature
(First digit shows 4 and dot flashes) (3)
4. 42
This function not used
(First digit shows 5 and dot flashes) (2)
5.-18
NOTE: Display will show A-32 if [STEP] is pressed after “9” appears.
Outlet water temp. change over time
(First digit shows 7 and dot flashes) (5)
7.
1
Return water temp. change over time
(First digit shows 8 and dot flashes) (5)
8.
1
This function not used
(First digit shows 9 and dot flashes) (6)
9.-32
Target outlet water temperature
(First digit shows 6 and dot flashes) (4)
24
6.190
IX - user interface quick reference
HARD LOCKOUT MODE
Boiler in hard lockout (requires manual RESET)
Display flashes first digit E
Code
E
Reason for hard lockout
and last two digits (lockout code) (see below)
Code
xx
Reason for hard lockout
00
Flame detected on start-up
18
Supply water temperature higher than 200°F
02
Ignition failed after 5 retries
19
Return water temperature higher than 190°F
03
Gas valve disconnected
25
Outlet temperature increased too fast
04
Power lost after lockout
28
No signal from blower; blower not running or defective blower motor
05
Internal control failure
29
Blower signal not “0” when it should be
06
Internal control failure
30
Max difference (b30) was too large for 20 successive times. Non adjustable default
max delta set to 100°F.
07
Internal control failure
31
Outlet temperature sensor short circuit
11
Internal control error
32
Return temperature sensor short circuit
12
Casting temperature switch open
36
Outlet temperature sensor open circuit
13
Internal control failure
37
Return temperature sensor open circuit
14
Internal control failure
44
Internal control failure
15
Internal control failure
60
Internal error reading parameters
16
Internal control failure
61
Air flow circuit failure
17
Internal control failure
65
Not enough blower driving force
25
X- Installation And Checkout Certificate
Boiler Model:
Boiler Serial Number:
Date of Installation:
Measured BTUH Input:
Boiler Location:
Altitude of Location:
Honeywell AM Kit Installed? (Yes/No):
Service Dates:
System Type (Give Brief Description):
Installation Instructions Have Been Followed
Checkout Procedure/Adjustments Performed
Maintenance/Service Issues Reviewed With Owner or Maintenance Person
Installation Manual Affixed Adjacent To or On Boiler
Installer/Technician’s Company:
Installer’s Name:
Company Address:
Company Phone Number:
Installer’s Signature:
26
27
28